Coating compositions

ABSTRACT

A coating composition is prepared containing a polymer emulsion which comprises a first polymer network which is intertwined on a molecular scale with a second polymer network.

This is a continuation of application Ser. No. 925,796, filed Oct. 31, 1986, which is a continuation-in-part of application, Ser. No. 911,081, filed Sep. 24, 1986 which is a continuation-in-part of application, Ser. No. 753685, filed Jul. 10, 1985, now U.S. Pat. No. 4,616,057 issued Oct. 7, 1986.

BACKGROUND OF THE INVENTION

This invention relates to a process for preparing a polymer emulsion containing colloidally suspended therein an interpenetrating polymer network wherein a first polymer network is intertwined on a molecular scale with a second polymer network and optionally additional polymer networks. The polymer emulsion of this invention is useful as a binder of fibers or fabrics, especially fiberfill.

Fiberfill is a generic term used to describe a variety of nonwoven fabrics for a variety of end uses. The common feature of all fiberfill products is a measure of loft or thickness in the fabric. This loft is a characteristic of value because it imparts insulation to outerwear and bed quilt stuffing, cushioning in furniture padding, dust holding capacity to filter media and resiliency to scrubbing pads. The most common construction of a fiberfill product is a loosely garnetted, cross-lapped or air laid web of 6 to 30 denier polyester staple fibers which is bonded (locked in its particular fiber arrangement) by an emulsion polymer binder. Fiberfill products can be made with other fibers, e.g. polyamide, cellulose acetate, rayon, glass, alone or in blends with each other. Some fiberfill is sold without a bonding agent but the material will lack durability, tensile strength and resiliency when compared to a bonded product. Bonding methods other than emulsion polymers, such as needle punching, and meltable fibers and powders are also used, but the polymer emulsion method produces the optimum strength/loft ratios for the majority of fiberfill markets.

The polymer emulsion product used as the binder is usually one of the following chemical types: polyvinylacetate, acrylic copolymers, styrene-butadiene copolymers or polyvinylchloride. Polyvinylacetate is the most common binder and in recent years it has been made white enough and strong enough to replace most of the acrylic polymer traditionally used. Polyvinylchloride is used where flame resistance is of prime concern and styrene-butadiene copolymers are used for special rubbery applications.

The characteristic of initial loft is unaffected by the chemical type of the binder used. However, initial loft is not the loft of value. Fiberfill products in their normal use are compressed, reducing the initial loft, and released many times. The true value of loft is how thick the fiberfill web is after repeated compression/recovery cycles. One drawback of current polymer bonded fiberfill technology is that temperatures over 100° F. will soften the binder and cause the fiberfill product to permanently lose loft if it is compressed at this elevated temperature. Temperatures of up to 180° F. are encountered in the shipping and use of many fiberfill products. Typically a fiberfill product, which may lose only 15% of its initial loft if compressed and released at 80° F., will lose more than 80% of its loft if tested the same way at only 120° F. Higher temperatures are expected to even more dramatically damage this loft recovery.

In the preparation of a coated cellulosic web, e.g. a paper web, there is used a pigment, such as clay or the like, sometimes with other materials such as, for example, a soluble pyrophosphate which may act to disperse the pigment in water and stabilize the pigment in water. This mixture, commonly termed a pigment "slip" or, since it usually contains clay, a clay "slip", is then compounded with a binder or adhesive material to produce a composition known in the art as a coating "color", which is useful for coating a cellulose web, e.g. a paper or paperboard web. Substantial quantities of the binder are used, and, accordingly, the composition and characteristics of the binder are of great importance in determining the qualities of the finished coated web. It is important that the binder contributes to the coating or the finished coated web a high degree of brightness, smoothness and gloss, and a good finish and feel after calendering. In addition to these basic qualities required in coatings, the coating color must flow smoothly and evenly so that it can be applied to the cellulosic web at sufficiently high speeds to be economical in ordinary coating processes; and the coating must have high strength, to permit subsequent printing on the coated paper without "picking," i.e. it must have good "pick" characteristics.

Polymer emulsions are useful as a coating binder for paper and paperboard. Paper is coated to provide a smoother surface with increased strength, whiteness and absorbability in order to provide a better surface on which to print. Coating formulations for paper and paperboard can contain a variety of binders including all-latex binders, protein-latex binders, all-starch binders or latex-starch blends. The end use of the paper and, in particular, the method by which it will be printed, may determine which binder type is used in the coating. The major printing method is the offset method in which both water (fountain solution) and an oil based ink are applied to the paper coating. The rate of absorption of the water layer and the ink into the coating is critical to producing a desirable high quality printing.

Styrene-butadiene copolymers are commonly used latex binders, followed by polyvinylacetate, vinylacetate-acrylic copolymers, ethylene-vinylacetate copolymers and all acrylic polymer emulsions. Styrene-butadiene and vinylacetate binders are widely used because of their low cost. The major drawback of styrene-butadiene binders is the poor water absorption giving high SIWA brightness values. High SIWA (simultaneous ink and water absorption test) brightness values mean the coating did not absorb the initially applied water layer and the subsequent ink application failed to penetrate this layer and absorb into the coating. The incomplete ink coverage produces a weak or spotty image. Vinyl acetate binders are often too water absorbent, resulting in press roll fountain solution milking. This problem is the converse of the high SIWA brightness problem. Fountain solution milking occurs when the coating absorbs so much water (fountain solution), that the coating becomes solubilized in the fountain solution and the binder and clay so dissolved give the solution a "milky" appearance. This condition can be predicted by the Adams Wet Rub Test.

Another area in which polymer emulsions are useful is in a coating especially as a binder for industrial and architectural coatings. Industrial and architectural coatings are applied to surfaces of all types, such as metal, wood, concrete, stone, plastic, plasterboard, glass and the like, to provide protection and decoration. Polymer emulsions are now used by industry as the binder of choice in a great variety of waterborne coatings because they are environmentally very desirable. Since solvent emissions into the atmosphere are a major concern, waterborne coatings are preferred to reduce such solvent emissions. Although organic solvent based coatings can still be used, these coating systems have become increasingly uneconomical, because expensive anti-pollution devices, such as afterburners or solvent recovery devices, have to be installed.

In architectural coatings which are for exterior coatings acrylic polymer emulsions dominate, because they have been used for many years and their outdoor properties such as ultraviolet resistance and lack of embrittlement with time have been proven on test fences and in actual practice for many years. Other polymer emulsions such as vinyl acetate-ethylene-vinyl chloride terpolymers have also found increasing use in outdoor architectural coatings because they have also shown to possess excellent properties. Indoor architectural coatings mostly contain vinyl acetate-ethylene copolymer- or vinyl acetate-acrylic copolymer emulsions.

The polymer emulsions that are used for industrial coatings include polyvinyl acetate and polyvinyl acetate copolymers for wood panel finishes, because they can be sanded better than most acrylic coatings. Polyacrylates are used in maintenance coatings for metal tanks and pipes, and as primers for automobiles. These are often deposited by electrocoating processes. Furniture finishes, appliance coatings and the like are also based on polyacrylates. There are some areas in the industrial coatings field where polymer emulsions have not yet been successfully used such as in coil prime- and top coatings. Coil coating primers are applied to continuous coils of bare metal, such as steel or aluminum stock, to protect the uncoated metal prior to fabricating the primed metal. Often a top coat is also applied so that the metal sheet is completely coated prior to sending it to a metal fabricator who converts it to useful metal products It is important for coil coatings to withstand the rigorous fabricating process, when the coated metal is converted to articles such as metal cabinets and the like, without damaging the previously applied coating. The coated metal is often bent and drawn during the fabricating process and therefore must possess toughness and extensibility. Many coatings will separate from the metal in places during this process which often necessitates an expensive refinishing procedure. Although solvent-based coil coatings have been used predominantly in the past, economics and environmental considerations dictate that aqueous coil coatings, primers as well as topcoats, are most desirable for industrial use.

The polymer emulsion prepared by the process of this invention provides a binder compound for fiberfill which provides improved resiliency and loft recovery to the bonded fiberfill products. This polymer emulsion is useful in bonding textile fibers in a fiberfill product or in any nonwoven product or even any traditional woven or knitted textile fabric. The polymer emulsion can also be used in a coating, especially as a coating binder for paper and paperboard. Other types of coatings in which the polymer emulsion is useful include the various industrial coatings such as maintenance coatings (e.g. for metal tanks, pipelines and other metal structures), coil coatings, can coatings, appliance coatings (e.g. for refrigerators, washing and drying machines), wood coatings (e.g. wood panels or furniture), floor coatings and sealers (e.q. floor polishes), automotive coatings (e.g. primers, top coats), leather coatings, concrete sealers and coatings, marine coatings, as well as architectural coatings such as house paints, both exterior and interior.

SUMMARY OF THE INVENTION

Briefly, the present invention provides a process for preparing a polymer emulsion containing an interpenetrating polymer network by forming a first polymer emulsion, mixing a second monomer emulsion with the first polymer emulsion, allowing the emulsion mixture to equilibrate and polymerizing the emulsion mixture providing a first polymer network which is intertwined on a molecular scale with the second polymer network. This polymer emulsion is useful in coatings, particularly as a coating binder for industrial coatings and architectural coatings.

DETAILED DESCRIPTION OF THE INVENTION

The aqueous polymer emulsion containing an interpenetrating polymer network is prepared by forming a first polymer emulsion. The first polymer emulsion can be prepared by conventional batch, semi-continuous or continuous polymerization procedures. These are taught, for example in U.S. Pat. Nos. 2754280, 2795564, 3732184 and in the book entitled "The Applications of Synthetic Resin Emulsion" by H. Warson, Ernest Benn Limited, London, 1972, pp. 85 to 132. The first polymer emulsion can be formed by polymerizing a monomer or a mixture of monomers (herein called a first monomer) with an active crosslinking agent. Alternatively the first polymer emulsion can be formed by emulsifying a polymer. Examples of emulsified polymers include polyethylene emulsions, polyester emulsions, polyurethane emulsions and the like.

The first polymer emulsion is mixed with a second monomer emulsion and then the emulsion mixture is allowed to equilibrate. By equilibration is meant allowing sufficient time for the second monomer to become absorbed into the first polymer. The mixing and equilibration allows the second monomer emulsion to be thoroughly mixed and dispersed throughout the first polymer emulsion on a molecular scale. The second monomer emulsion can be added either as an emulsion or as a monomer or mixture of monomers which will emulsify during mixing with the first polymer emulsion.

Then, after thorough mixing and equilibration the emulsion mixture is polymerized providing a first polymer network which is intertwined on a molecular scale with the second polymer network, i.e. an interpenetrating polymer network is formed. Optionally, a third monomer emulsion can then be mixed in, equilibrated, followed by polymerization or further additional monomer emulsions can likewise be intertwined in the polymer networks. When the polymer emulsion is subsequently applied, dried and heated the physical and chemical bonding of the first polymer network with the second polymer network is completed.

Because of the interpenetrating network formed, desirable physical properties are achieved. Dual Tg (glass transition temperature) properties have been observed wherein the polymer has the Tg of both the first polymer and the second polymer. This is especially useful in the application of the polymer emulsion wherein modulus, tensile strength and desirable film forming properties can be adjusted by varying the ratio of the first and second polymers comprised in the interpenetrating network. Because the first and second networks are intertwined on a molecular scale higher tensile strength has been observed as well as higher modulus and higher impact strength at temperatures intermediate the Tg's of the first polymer and the second polymer.

The monomers which are polymerized in accordance with the present invention are vinyl monomers, ethylenically unsaturated compounds. Examples of monoethylenically unsaturated monomers are: vinyl esters of alkanoic acids having from 1 to about 18 carbon atoms, such as vinyl formate, vinyl acetate, vinyl propionate, vinyl butyrate, vinyl isobutyrate, vinyl valerate, vinyl 2-ethylhexanoate, vinyl isooctanoate, vinyl nonoate, vinyl decanoate, vinyl pivalate, vinyl ester (e.g. Versatic Acid-TM, a branched carboxylic acid, marketed by the Shell Oil Corporation), vinyl laurate, and vinyl stearate; also alpha-olefins, such as ethylene, propylene, butylene, isobutylene, and pentene and the like; also maleate, fumarate, and itaconate esters of C₁ -C₈ alcohols, such as dibutyl maleate, dibutyl fumarate, dibutyl itaconate; also alkyl acrylates with an alkyl group having from 1 to 18 carbon atoms, such as methyl, ethyl, n-butyl, sec-butyl, the various isomeric pentyl, hexyl, heptyl, and octyl (especially 2-ethylhexyl), lauryl, cetyl, stearyl and like groups; also alkyl esters of methacrylic acid with an alkyl group having from 1 to about 18 carbon atoms, such as methyl, ethyl, propyl, n-butyl, n-hexyl, 2-ethylhexyl, n-octyl, lauryl, cetyl, stearyl and like groups; also vinyl alkyl ethers, having an alkyl group with 1 to 18 carbon atoms, such as methyl vinyl ether, ethyl vinyl ether, butyl vinyl ether and stearyl vinyl ether. Examples of monomers also include diene monomers, such as butadiene, chloroprene, and isoprene and similar compounds. Other monomers include aromatic vinyl monomers, such as styrene, alphamethylstyrene, vinyl toluene, 2-bromostyrene, and p-chlorostyrene; also acrylonitrile; also vinyl halide monomers, such as vinyl chloride and vinylidene chloride; also benzyl acrylate and t-butyl acrylate; also vinyl esters of aromatic acids, such as vinylbenzoate.

Preferably the polymer present in the first polymer emulsion is either polymethyl methacrylate, polyvinyl acetate, polybutylacrylate, vinylchloride ethylene copolymer, vinylacetate ethylene copolymer, polystyrene or polyacrylonitrile or copolymers of these with other monomers mentioned above, while the second polymer differs from the first polymer and preferably is based upon a monomer such as acrylo nitrile, methyl methacrylate, butyl acrylate, styrene or mixtures thereof.

In order to obtain desirable dual Tg properties, the polymer in the first polymer emulsion and the polymer derived from the second monomer emulsion can be chosen so, for example, one has a Tg greater than the other. Different pairs of polymers can be chosen to exhibit useful properties over different temperature ranges. For example, because of polystyrene's higher Tg, upon interpenetrating a polyvinyl acetate network it will extend the modulus and reduce distortion of the matrix at elevated temperatures.

In general, the various combinations of monomers can be chosen for the first polymer emulsion or the second monomer emulsion. However, the monomer chosen for the first monomer emulsion cannot be an inhibitor to or retard the polymerization of the monomer in the second monomer emulsion. Since acrylonitrile is an inhibitor to the polymerization of vinyl acetate, the vinyl acetate must be in the first polymer emulsion while the acrylonitrile is in the second monomer emulsion. Thus, in a preferred embodiment, the first polymer emulsion contains polyvinyl acetate, vinylacetate-ethylene copolymer or vinylacetate-butylacrylate copolymer, while the second monomer emulsion contains either styrene, methyl methacrylate, acrylonitrile or butylacrylate, or mixtures thereof.

When the resultant polymer emulsion is to be used in a coating, preferred polymer combinations include wherein the first polymer network contains either a polyvinylacetate, a vinylacetate-ethylene copolymer, a vinylchloride ethylene copolymer, a polyvinyl propionate or a vinylacetate-acrylic copolymer (preferably where the acrylic comonomer is a methyl, ethyl, butyl or 2-ethyl hexyl acrylate) and wherein the second polymer network contains either polystyrene, an acrylonitrile-acrylate copolymer, a styrene-butadiene copolymer or a styrene acrylic copolymer. In a preferred polymer combination the first polymer contains an ethylene-vinylacetate copolymer and the second polymer contains polystyrene, preferably at level of 5 to 40% on a solids by weight basis of the emulsion.

In preparing coating compositions the emulsions of the present invention are often prepared by copolymerizing the principal monomers also with specialty monomers to obtain special properties. Thus wet adhesion promoting monomers, corrosion inhibiting monomers, flame retarding monomers and dyestuff monomers can also be incorporated into the emulsion polymer by copolymerization with the principle monomers. Examples of wet adhesion promoting monomers are disclosed in U.S. Pat. No. 4,426,503; U.S. Pat. No. 4,429,095 and U.S. Pat. No. 4,260,533. Examples of corrosion inhibiting monomers are disclosed in U.S. Pat. No. 3,202,534 and U.S. Pat. No. 3,224,908. Examples of flame retarding monomers are disclosed in U.S. Pat. No. 3,892,578 and U.S. Pat. No. 4,386,036. Examples of dyestuff monomers are disclosed in U.S. Pat. No. 3,557,048.

The process of the present invention provides an interpenetrating network of polymers which are generally physically incompatible in that the polymers are not soluble in one another. In addition, this process provides a means of combining polymers which cannot readily be formed by copolymerization of their monomers. For example, vinyl acetate and styrene cannot generally be copolymerized and mixing or blending of the two polymers in emulsion form does not result in a polymer having desirable properties (e.g. poor pick strength).

The first polymer emulsion and optionally the second monomer emulsion contain an active crosslinking agent. By the term "active crosslinking agent" is meant a functional monomer which immediately provides crosslinking and branching of the polymer during the initial formation of the emulsion polymer (i.e. during the polymerization step) to increase the molecular weight of the emulsion polymer Subsequent drying or other curing techniques are not required for the crosslinking and branching of the emulsion polymer by the active crosslinking agent. Monomers of this type generally comprise compounds which contain 2 to 5 ethylenically unsaturated groups in one molecule separated by an ester or ether group, or by an aromatic or nitrogenous ring structure, where the unsaturated groups are capable of undergoing addition polymerization by free radical means. Suitable active crosslinking agents include alkylene glycol diacrylates and methacrylates, such as ethylene glycol diacrylate, 1,3-butylene glycol diacrylate, propylene glycol diacrylate, triethylene glycol dimethacrylate etc., 1,3-glycerol dimethacrylate, 1,1,1-trimethylol propane dimethacrylate, 1,1,1-trimethylol ethane diacrylate, pentaerythritol trimethacrylate, sorbitol pentamethacrylate, methylene bismethacrylamide, divinyl benzene, vinyl methacrylate, vinyl crotonate, vinyl acrylate, divinyl adipate; also di- and tri-allyl compounds, such as triallyl cyanurate, triallyl isocyanurate, diallyl phthalate, allyl methacrylate, allyl acrylate, diallyl maleate, diallyl fumarate, diallyl itaconate, diallyl malonate, diallyl carbonate, triallyl citrate, triallyl aconitate; also divinyl ether, ethylene glycol divinyl ether and the like. The amount of active crosslinking agent in the polymer emulsion of the present invention is from about 0.01 to 1.0 percent, preferably from about 0.05 to 0.25 percent by weight of the polymer.

The first polymer emulsion or the second monomer emulsion, preferably both, additionally contain a latent crosslinking agent. By the term "latent crosslinking agent" is meant a polyfunctional monomer wherein a portion of the functionality enters into the polymerization with other monomers in the polymer emulsion, with the residual functionality causing crosslinking of the polymer upon the subsequent application of energy generally by applying heat, e.g. by drying and curing of the latex particles, often in the presence of a catalyst, or by applying radiation. The latent crosslinking agent provides thermosetting characteristics to the polymer emulsion. Upon the subsequent application of energy the latent crosslinking agent forms an insoluble crosslinking network, with the crosslinking being triggered generally by heat or radiation after the polymer emulsion has been formed and applied. Examples of latent crosslinking agents are: N-alkylolamides of alpha, beta ethylenically unsaturated carboxylic acids having 3-10 carbons, such as N-methylol acrylamide, N-ethanol acrylamide, N-propanol acrylamide, N-methylol methacrylamide, N-ethanol methacrylamide, N-methylol malemide, N-eethylol maleamide, N-methylol maleamic acid, N-methylol maleamic acid esters; the N-alkylol amides of the vinyl aromatic acids, such as N-methylol-p-vinylbenzamide and the like; also N-(alkoxymethyl) acrylates and methacrylates, where the alkyl group has from 1-8 carbon atoms, such as N-(methoxymethyl) acrylamide, N-(butyoxymethyl) acrylamide, N-(methoxymethyl) methacrylamide; N-methylol allyl carbamate and the N-alkoxymethyl derivatives such as N-(butyoxymethyl) allyl carbamate and N-(methoxymethyl) allyl carbamate and the like, and mixtures of these monomers with allyl carbamate, acrylamide or methacrylamide. Epoxy containing monoethylenically unsaturated compounds, such as glycidyl acrylate, glycidyl methacrylate and vinyl glycidyl ether function as latent crosslinking monomers often in conjunction with mono- and diethylenically unsaturated carboxylic acids, such as acrylic, methacrylic and itaconic acid, when catalyzed with an alkaline catalyst, such as potassium or sodium carbonate, diethylenetriamine and the like. Hydroxyethyl acrylate, hydroxypropyl acrylate and the corresponding methacrylates provide latent crosslinking when combined with N-alkylolamides of alpha, beta ethylenically unsaturated acids having 3-10 carbon atoms or with the acids themselves by ester formation. Another group of latent crosslinking monomers is described in U.S. Pat. Nos. 3,678,098 and 4,009,314. These are cationic chlorohydrin compounds having the following formula: ##STR1## The crosslinking reaction of these monomers is also catalyzed by the alkaline compounds mentioned above. The amount of latent crosslinking agent in the polymer of the present invention is about from 0.5 to 10 percent, preferably from about 2 to 6 percent by weight of the polymer.

The emulsions of the present invention are prepared in the presence of suitable anionic, cationic or nonionic emulsifiers or mixtures thereof. Optionally, protective colloids, illustrated by polyvinyl alcohol and hydroxyethyl cellulose, may also be present. Suitable nonionic emulsifying agents include alkylphenoxypolyethoxyethanols having alkyl groups of about 7 to 18 carbon atoms and 5 to 60 or more oxyethylene units, such as octylphenoxypolyethoxyethanols, methyloctylphenoxypolyethoxyethanols, nonylphenoxypolyethoxyethanols, dodecylphenoxypolyethoxyetnanols; also ethylene oxide derivatives of long chained carboxylic acids, such as lauric, myristic, palmitic, oleic, and stearic acid, containing 5 to 60 oxyethylene units per molecule; also analogous ethylene oxide condensates of long-chained alcohols, such as octyl, decyl, lauryl, stearyl and cetyl alcohols, ethylene oxide derivatives of etherified or esterified polyhydroxy compounds having a hydrophobic component, such as lauric, myristic, palmitic, oleic, and stearic acid, containing 10 to 60 oxyethylene units per molecule; also analogous ethylene oxide condensates of long-chained alcohols, such as octyl, decyl, lauryl, stearyl, and cetyl alcohols, ethylene oxide derivatives of etherified or esterified polyhydroxy compounds having a hydrophobic hydrocarbon chain, such as sorbitan monostearate containing 10 to 60 oxyethylene units; also block copolymers of ethylene oxide and propylene oxide comprising a hydrophobic propylene oxide section combined with one or more hydrophilic ethylene oxide sections. Suitable anionic emulsifying agents include higher fatty alcohol sulfates, such as sodium lauryl sulfate, the alkylaryl sulfonates, such as the sodium salt of t-octylphenyl sulfonate, the sodium dioctyl sulfosuccinates, disodium fatty alkyl alkanolamide sulfosuccinate, and the ammonium salt of a sulfate or phosphate ester of an alkylphenoxy poly(ethyleneoxy) ethanol, where the oxyethylene content is from 3 to 30 moles per alkylphenol. Suitable cationic emulsifiers include N-dodecyl trimethyl ammonium chloride, and N-vinyl benzyl trimethyl ammonium chloride and the like. Generally, the polymer emulsions of this invention contain from 1 to 10 percent, preferably from 3 to 6 percent, emulsifiers based on the weight of the monomers (solids).

An ethylenically unsaturated carboxylic acid is also preferably added to the polymer emulsions to provide mechanical stability to the emulsion. Generally, an ethylenically unsaturated mono- or dicarboxylic acid may be used to provide the carboxyl functionality to the copolymer. Examples of suitable acids include the monocarboxylic ethylenically unsaturated acids such as acrylic, crotonic, and methacrylic acid; the dicarboxylic ethylenically unsaturated acids such as maleic, fumaric, itaconic, and citraconic acid, as well as the half esters of these dicarboxylic acids with C₁ -C₁₂ alcohols. Examples of these monomeric acids are monomethylmaleate, monoethylmaleate, monobutylmaleate, and mono(2-ethylhexyl)maleate and the like. The polymer emulsions preferably contain from 0.1 to 0.5 percent of unsaturated carboxylic acids based on the weight of the monomers (solids).

In one embodiment, in a polymerization process which can be used in making the first polymer emulsion of the invention an aqueous phase is prepared first containing water, a small portion of a nonionic emulsifier, sometimes also a mixture of anionic and nonionic emulsifiers, and a very small amount of ferrous sulfate, being a redox component in the catalyst system or the finishing catalyst system for the polymer emulsion. The aqueous phase is purged well with nitrogen, and heated to polymerization temperatures (e.g. 40° to 70° C.). A small portion of monomer (and redox component for certain systems such as vinylacetate-ethylene copolymers), is then added followed by a suitable amount of initial catalyst, most often from about 1 to 3 percent based on the weight of the initial monomer charge. Often it is advantageous to use potassium persulfate as the catalyst because the resulting polymer has better resistance to heat discoloration. But sodium or ammonium persulfates can also be used. After the emulsion polymerization has initiated, the rest of the monomers are gradually added to the reaction mixture, often emulsified in water together with the latent crosslinking agents and the active crosslinking agents. Generally, the gradual addition of the monomers is carried out over a time period of one to five hours. More catalyst solution (and redox component in certain systems) is also added gradually to maintain the polymerization reaction. Often cooling is applied to the reaction vessel by means of a waterbath to remove the excess heat of polymerization Usually, a total of 0.2 to 1 percent of catalyst (and 0.2 to 1% of redox component in certain systems) based on the weight of the monomers, is added over the course of the emulsion polymerization. After all the monomer has been added optionally a small amount of an organic peroxide, such as t-butyl hydroperoxide and cumene hydroperoxide, and the like can be added for the finishing step, together with a small amount of a reducing agent, such as sodium metabisulfate, sodium formaldehyde sulfoxylate, zinc formaldehyde sulfoxylate and ascorbic acid. In place of an organic peroxide, hydrogen peroxide or persulfates, such as potassium, sodium or ammonium persulfates may also be used. The terminal catalyst necessary to finish the the reaction is generally about 10 to 30 percent by weight of the total amount of catalyst consumed during the reaction. The reducing agent is ordinarily added in the necessary equivalent amount. Normally no buffering agent is required to keep the pH between 3 and 5. If necessary, dilute ammonia or a dilute solution of sodium acetate or sodium bicarbonate may be added from time to time to adjust the pH within those limits. Others auxiliary agents may be added to the finished polymer emulsion, such as defoamers, biocides and the like.

After the first polymer emulsion is cooled a second monomer or mixture of monomers is introduced into the reactor, preferably as fast as possible. The second monomer can be either added as an emulsion to the first polymer emulsion or as a monomer or mixture of monomers which are emulsified during mixing with the first polymer emulsion. Water, emulsifier and a small amount of ferous sulfate (redox component) are also often added either with the second monomer or after equilibration.

Following thorough mixing and equilibration (e.g. 10 to 60 minutes) of the first polymer emulsion and second monomer emulsions a second polymerization step is initiated by the addition of catalyst solution and then the reducing solution.

The polymer emulsion of this invention generally contains from 5 to 95%, preferably 60 to 95% on a solids by weight basis of the first polymer emulsion and 5 to 40% on a solids by weight basis of the second polymer emulsion.

The polymer emulsions of the present invention are useful as binders, adhesives and coatings. These polymer emulsions when used as binders provide high temperature resiliency to bonded fiberfill products. The polymer emulsions are useful in bonding textile fibers in a fiberfill product or other nonwoven product or even in traditional woven or knitted textile fabrics. Generally, based on the weight of the fiberfill product the binder can comprise 2 to 50%.

The polymer emulsions of this invention are useful in coatings, particularly as a coating binder for paper and paper board. The coating containing the polymer emulsion can be used to provide a smoother surface and increased strength, whiteness and gloss to a paper or paperboard product. In addition to the polymer emulsion binder the coating can contain proteins, polyvinyl alcohol, alginates, resins or modified or unmodified starches as binders. Other conventional ingredients can be included in the coating such as pigments (including titanium dioxide and/or calcium carbonate), lubricants (e.g. calcium stearate), insolubilizers (e.g. glyoxal resins to crosslink starch), defoamers, biocides (to prevent mildew), preservatives and the like. Paper can be treated with the coating by a variety of coating techniques including size press, air knife coating, blade coating, gravure coating, puddle coating, spray or kiss roll. Some specialty papers apply polymer emulsions with or without fillers with these processes. The unique characteristics of these specialty papers can be enhanced and/or delivered at a lower cost by using the polymer emulsions of this invention.

Because of their unique mechanical properties, such as dual glass transition tempertures and relatively high moduli with exceptional toughness and solvent resistance, the polymer emulsions of this invention are useful in coatings particularly as binders in industrial and architectural coatings. The polymer emulsions of this invention provide coatings with improved impact resistance, wear and resistance to damage from bending when they are used on metals, and improved resistance to dimensional changes and ability to be sanded when they are used as wood coatings. Interior and exterior architectural coatings made with the polymer emulsions of this invention have exceptional scrubbability. They are also hydrolysis resistant which makes them suitable to coat concrete.

In general, coating formulations are prepared by first dispersing the prime pigments as well as the extender pigment, or a mixture of pigments in water. Prime pigments include both rutile and anatase grades of titanium dioxide, and zinc oxide, as well as the color pigments: Hansa Yellow, phthalocyanine blue and green, quinacridones such as Red B, Red Y, Violet R, and Orange RK; also Cadmium Red, Chrome Yellow, Molybdate Orange, Ferric Oxide, Carbon Black: also metallic pigments such as aluminum, bronze and stainless steel flake. Extender pigments include calcium carbonate, calcium silicate, mica, clay, silica, barium sulfate and the like.

Dispersants, both organic and inorganic types, are used to facilitate the dispersion of the pigments in water. Inorganic dispersants include, tetrapotassium pyrophosphate, potassium tripolyphosphate and the like. Organic dispersants include, alkali or ammonium salts of polycarboxylic acids, such as polymethacrylic acid, polyacrylic acid, and maleic anhydride-isobutylene copolymers; also ditertiary acetylenic glycols and the like. After the pigments are well dispersed other auxiliary materials are often added to the pigment slurry, for example, wetting agents, to facilitate the wetting of surfaces to be coated as well as wetting the hydrophobic pigments used in the coating. Wetting agents include surface active agents such as sulfosuccinates, ethylene oxide condensates of alkylphenols, and the like. Filming aids are also often added to the coating. These include ethylene glycol monobutyl ether, diethyle-ne glycol monobutyl ether, hexylene glycol, 2-ethylhexyl acetate and the like. Plasticizers are added often, such as dibutyl phthalate, dioctyl phthalate, to soften hard polymers more permanently. Defoamers such as 2-ethyl hexanol are also employed when needed. Thickeners are added to control the coating viscosity; these include high molecular weight polyacrylic acids; cellulosics, such as carboxymethylcellulose or hydroxyethyl cellulose, or polyvinyl alcohol. Biocides to prevent mildew, and preservatives to prevent degradation of thickeners and surface active agents are also often added. The polymer emulsion is then added to the pigment dispersion with slight agitation, followed by the addition of crosslinking resins such as melamine formaldehyde or urea formaldehyde resins. The pH of the coating is often adjusted with amines such as triethanol amine or morpholine and the like, or aqueous ammonia solution.

The coating is applied by various coating methods. Coating methods are described in detail in the "Encyclopedia of Polymer Science and Engineering" Second Edition, John Wiley, New York (1985, Volume 3, pages 552-615). They include roller coating, reverse roller coating, blade coating, knife coating, dip coating, kiss roll coating, spray coating, electrodeposition, and often, application of the coating by paint brush or roller.

Industrial coatings are applied in a factory to various substrates such as aluminum™or steel sheets, or woodpanels, also to automobiles, appliances, and machines, such as farm implements, and the like. Marine coatings are applied to ships and other surfaces coming in contact with water. Oil tanks, pipelines, fences and the like are often coated in place. Cans and bottles, made from both glass and plastic, can be coated in an automatic coating line.

Architectural coatings are those coatings which are put on structures such as houses and buildings which are built using a variety of building materials such as wood, metals, concrete, stone and the like. The polymer emulsions of this invention are particularly suited for coating these materials. Some times the coatings are used without pigments as so-called clear coatings.

The polymer emulsions of this invention, because of the aforementioned excellent physical properties, and because of their generally lower cost, are uniquely suitable for a wide variety of coatings.

EXAMPLE 1

A polymer emulsion is prepared as follows containing a polymer which is an interpenetrating network of polyvinyl acetate and polystyrene.

The following was charged to a 100 gal. (379 liter) stainless steel pilot reactor equipped with a variable agitator, temperature control system, feedpumps, means for purging the reactor with nitrogen, and a jacket for heating and cooling:

    ______________________________________                                         Water             140    lbs. (63.5 kg)                                        Triton X 305 (1)  6      lbs. 10 oz. (3 kg)                                    Emcol K8300 (2)   8      oz. (227 g)                                           ______________________________________                                    

The contents of the reactor were heated to 67° C. after which the reactor was purged with nitrogen. After the heat-up and purge the following monomer was added to the reactor:

    ______________________________________                                         Vinyl acetate 26 lbs. (11.8 kg)                                                ______________________________________                                    

This was followed by the addition of the initial catalyst solution:

    ______________________________________                                         Water                10    lbs. (4.5 kg)                                       Potassium persulfate 8     oz. (227 g)                                         ______________________________________                                    

The polymerization initiated within 5 minutes as indicated by a 2° C. rise in temperature of the reactor. The following first monomer emulsion, made up previously, was then added gradually by means of an addition pump at a rate of 1.56 lbs. (0.71 kg)/minute over a 31/2 hour period:

    ______________________________________                                         Water               58     lbs. (26.3 kg)                                      Emcol K8300 (2)     8      lbs. 8 oz. (3.9 kg)                                 Triton X 305 (1)    2      lbs. 4 oz. (1.0 kg)                                 N-Methylol acrylamide (49%)                                                                        19     lbs. (8.6 kg)                                       Acrylamide (50%)    2      lbs. (0.9 kg)                                       Monoethylmaleate    12     oz. (340 g)                                         JPS Sequesterent (5)                                                                               5      oz. (142 g)                                         Vinyl acetate       238    lbs. (108 kg)                                       Triallyl cyanurate  5      oz. (142 g)                                         ______________________________________                                    

The temperature of the reactor content was allowed to rise to 80° C. and was maintained there by the gradual addition at a rate of 0.362 lbs. (0.164 kg)/minute over a 31/2 hour period of the following catalyst solution:

    ______________________________________                                         Water                75    lbs. (34 kg)                                        Potassium persulfate 9     oz. (255 g)                                         ______________________________________                                    

After 31/2 hours, when all the first monomer emulsion and catalyst solution had been added to the reactor the following finishing catalyst solution was added:

    ______________________________________                                         Water                1     lb. (.45 kg)                                        Potassium persulfate 2     oz. (57 g)                                          ______________________________________                                    

The temperature of the batch was maintained at 80° C. for an additional 30 minutes, after which the first polymer emulsion was cooled to 60° C. At this point a second monomer emulsion was introduced into the reactor, as fast as possible, in about 10 minutes, and mixed with the first polymer emulsion. The second monomer emulsion had been prepared before containing:

    ______________________________________                                         Water                50     lbs. (22.7 kg)                                     Emcol K8300 (2)      3      lbs. (1.4 kg)                                      Triton X 305 (1)     3      lbs. (1.4 kg)                                      N-Methylol acrylamide (49%)                                                                         5      lbs. (2.3 kg)                                      Styrene              100    lbs. (45.4 kg)                                     Ferrous sulfate      1      gram                                               ______________________________________                                    

The temperature of the reactor content was maintained at 60° C. and allowed to equilibrate (1/2 hour) while the reactor was again purged with nitrogen after which the following catalyst solution was added to the reactor:

    ______________________________________                                         Water                19    lbs. (8.6 kg)                                       Potassium persulfate 1     lb. (0.5 kg)                                        t-butyl hydroperoxide                                                                               8     oz. (227 g)                                         ______________________________________                                    

The second polymerization step was initiated by adding half of the following reducing solution:

    ______________________________________                                         Water                16    lbs. (7.3 kg)                                       Hydrosulfite AWC (3) 6     oz. (170 g)                                         ______________________________________                                    

The temperature of the batch increased rapidly to 80° C., at which point the other half of the reducing solution was added to the reactor. The temperature of the batch was then maintained at about 80° C. for an additional 30 minutes, after which the polymer emulsion was cooled to room temperature. The following post- add was then added:

    ______________________________________                                         Water                4     lbs. (1.8 kg)                                       Zinc nitrate solution in                                                                            14    oz. (397 g)                                         water (50%)                                                                    Phosphoric acid      7     oz. (198 g)                                         ______________________________________                                    

followed by a second post- add as follows:

    ______________________________________                                         Water                2     lbs. (0.9 kg)                                       Proxel GXL (4)       11/2  oz. (43 g)                                          Formaldehyde (37%)   11/2  oz. (43 g)                                          ______________________________________                                    

A total of 55 lbs. (24.9 kg) of rinsewater was added to the emulsion for clean up of the pumps and lines.

Notes:

(1) Triton X 305 is a 70 percent solution in water of an octylphenoxypolyethoxyethanol containing 30 moles of oxyethanol per mole of octyl phenol. It is supplied by the Rohm & Haas Company.

(2) Emcol K8300 is a 40 percent solution in water of disodium fatty alkyl alkanolamide sulfosuccinate supplied by the Witco Chemical Company.

(3) Hydrosulfate AWC is a brand of sodium formaldehyde sulfoxylate supplied by the Diamond Shamrock Company.

(4) Proxel GXL is a biocide supplied by the ICI Company.

(5) JPS Sequesterant is a brand of diethylenetriamine pentaacetic acid supplied by the Intex Products Company.

The polymer emulsion thus obtained had the following properties:

    ______________________________________                                         solids (30 min. at 130° C. drying)                                                            46.3%                                                    pH                    3.5                                                      viscosity (Brookfield at 50 RPM)                                                                     78       cps                                             intrinsic viscosity (measured in                                                                     1.5      dl/g                                            N-methyl pyrrolidone at (30° C.) (6)                                                          1.5      dl/g                                            particle size (by light transmission) (7)                                                            0.33     microns                                         ______________________________________                                    

Notes:

(6) In measuring the intrinsic viscosity, a 1 ml sample of the polymer emulsion is added to 100 ml of N-methyl pyrrolidone, and the mixture is agitated and filtered. The flowtime of the solution so prepared is then compared at 30° C. with the flow time of the N-methyl pyrrolidone solvent using a Ubbelohde viscometer (obtained from the Cannon Instrument Company) the relative viscosity is the fraction obtained by dividing the flowtime of the solution by the flowtime of the solvent. The Huggins equation is then used to calculate the intrinsic viscosity from the relative viscosity measurement and from the polymer solids content in grams per 100 ml of solution. The use of the Huggins equation for intrinsic viscosity calculations is described in detail in the "Encyclopedia for Polymer Science and Technology", (Wiley, New York, 1971) Vol. 15, page 634.

(7) The particle size was measured by light transmission using a Beckman spectrophotometer (Spectronic 20). The method is described in detail in "Official Digest of the Paint and Varnish Industry", February 1959, pages 200-213.

EXAMPLE 2

A polymer emulsion is prepared containing a polymer which is an interpenetrating network of polyvinyl acetate and polymethyl methacrylate.

The following was charged to a 100 gal. (379 liter) stainless steel pilot reactor equipped with a variable agitator, temperature control system, feedpumps, means for purging the reactor with nitrogen, and a jacket for heating and cooling.

    ______________________________________                                         Water             140    lbs. (63.5 kg)                                        Triton X 305 (1)  6      lbs. 10 oz. (3 kg)                                    Emcol K8300 (2)   8      oz. (227 g)                                           ______________________________________                                    

The contents of the reactor were heated to 67° C. after which the reactor was purged with nitrogen. After the heat-up and purge the following monomer was added to the reactor:

    ______________________________________                                         Vinyl acetate 26 lbs. (11.8 kg)                                                ______________________________________                                    

This was followed by the addition of the initial catalyst solution:

    ______________________________________                                         Water                10    lbs. (4.5 kg)                                       Potassium persulfate 8     oz. (227 g)                                         ______________________________________                                    

The polymerization initiated within 5 minutes as indicated by a 2° C. rise in temperature of the reactor. The following first monomer emulsion, made up previously, was then added gradually by means of an addition pump at a rate of 1.56 lbs. (0.71 kg)/minute over a 31/2 hour period:

    ______________________________________                                         Water               58     lbs. (26.3 kg)                                      Emcol K8300 (2)     8      lbs. 8 oz. (3.9 kg)                                 Triton X 305 (1)    2      lbs. 4 oz. (1.0 kg)                                 N-Methylol acrylamide (49%)                                                                        19     lbs. (8.6 kg)                                       Acrylamide (50%)    2      lbs. (0.9 kg)                                       Monoethylmaleate    12     oz. (340 g)                                         JPS Sequesterent (5)                                                                               5      oz. (142 g)                                         Vinyl acetate       238    lbs. (108 kg)                                       Triallyl cyanurate  5      oz. (142 g)                                         ______________________________________                                    

The temperature of the reactor content was allowed to rise to 80° C. and was maintained there by the gradual addition at a rate of 0.362 lbs. (0.164 kg)/minute over a 31/2 hour period of the following catalyst solution:

    ______________________________________                                         Water                75    lbs. (34 kg)                                        Potassium persulfate 9     oz. (225 g)                                         ______________________________________                                    

After 31/2 hours, when all the first monomer emulsion and catalyst solution had been added to the reactor the following finishing catalyst solution was added:

    ______________________________________                                         Water               1      lb. (.45 kg)                                        Potassium persulfate                                                                               11/2   oz. (57 g)                                          ______________________________________                                    

The temperature of the batch was maintained at 80° C. for an additional 30 minutes, after which the first polymer emulsion was cooled to 60° C. At this point a second monomer emulsion was introduced into the reactor as fast as possible, in about 10 minutes, and thoroughly mixed with the first polymer emulsion. The second monomer emulsion had been prepared before containing:

    ______________________________________                                         Water                50     lbs. (22.7 kg)                                     Emcol K8300 (2)      3      lbs. (1.4 kg)                                      Triton X 305 (1)     3      lbs. (1.4 kg)                                      N-Methylol acrylamide (49%)                                                                         5      lbs. (2.3 kg)                                      Methyl methacrylate  100    lbs. (45.4 kg)                                     Ferrous sulfate      1      gram                                               ______________________________________                                    

The temperature of the reactor content was maintained at 60° C. and allowed to equilibrate (about 1/2 hour), while the reactor was again purged with nitrogen after which the following catalyst solution was added to the reactor:

    ______________________________________                                         Water                19    lbs. (8.6 kg)                                       Potassium persulfate 1     lb. (0.5 kg)                                        t-butyl hydroperoxide                                                                               8     oz. (227 g)                                         ______________________________________                                    

The second polymerization step was initiated by adding half of the following reducing solution:

    ______________________________________                                         Water                16    lbs. (7.3 kg)                                       Hydrosulfite AWC (3) 6     oz. (170 g)                                         ______________________________________                                    

The temperature of the batch increased rapidly to 80° C., at which point the other half of the reducing solution was added to the reactor. The temperature of the batch was then maintained at about 80° C. for an additional 30 minutes, after which the polymer emulsion was cooled to room temperature. The following post- add was then added:

    ______________________________________                                         Water                4     lbs. (1.8 kg)                                       Zinc nitrate solution                                                                               14    oz. (397 g)                                         in water 50%                                                                   Phosphoric acid      7     oz. (198 g)                                         ______________________________________                                    

followed by a second post- add as follows:

    ______________________________________                                         Water                2     lbs. (0.9 kg)                                       Proxel GXL (4)       11/2  oz. (43 g)                                          Formaldehyde (37%)   11/2  oz. (43 g)                                          ______________________________________                                    

A total of 60 lbs. (24.9 kg) of rinsewater was added to the emulsion for clean up of the pumps and lines.

The polymer emulsion thus obtained had the following properties:

    ______________________________________                                         solids (30 min at 130° C. drying)                                                             45.0%                                                    pH                    4.0                                                      viscosity (Brookfield at 50 RPM)                                                                     32       cps                                             intrinsic viscosity (measured in                                                                     2.3      dl/g                                            N-methyl pyrrolidone at 30° C.) (6)                                     particle size (by light transmission) (7)                                                            0.27     microns                                         ______________________________________                                    

EXAMPLE 3

A typical fiberfill product for quilt stuffing was constructed of 6 denier 2" staple length polyester fiber with garnetted and crosslapped webs to a weight of 4oz./yd². This web was then spray bonded with a commercially available polyvinylacetate emulsion polymer (SUNCRYL RW 41SP from Sun Chemical Corporation), and the polymer emulsion as prepared in Examples 1 and 2, producing a final fiberfill product composed of 82% fibers and 18% bonding polymer.

The binder mix is prepared in a tank by diluting the emulsions with water to a 22% nonvolatile content. This mix is pumped with reciprocating airless pumps at a pressure of 300 psi and delivered through spray nozzles of 0.018 inch diameter which traverse the polyester fiber web. The polyester web is passed under the traversing sprays so as to achieve a uniform application of the bonding mix. The web and applied mix are passed through a forced air oven to remove the water and coalesce the binder polymer onto the fibers. The web is turned over and the process repeated on the back side. Finally the web is passed through the oven a third time to cure the binder, rendering it durable and resistant to water and solvent interactions.

The residual loft value was simulated by the following test. Ten inch by ten inch squares of the fiberfill material are cut and stacked vertically. The height of this stack is measured (H₁). The stack is then compressed by placing weights on top of the stack. A typical weight of 20 pounds usually reduces the initial stack height by 50 to 75%. The stack is left in this compressed state for a period of time (1 hour is typical) at a stated temperature and then the weight is removed. The stack of fiberfill is allowed to recover for a further period of time (10 minutes is typical) and the height is again measured (H₂). The % recovery is stated as a ratio of the final height to the initial height: ##EQU1##

Table 1 shows % recovery values of a 6 layer stack compressed with 0.2 psi (20 lbs. on a 10"×10" square) for 16 hours and then allowed to recover for 1 hour at the stated temperatures.

                  TABLE 1                                                          ______________________________________                                         Polyvinyl acetate  Example 2 Example 1                                         ______________________________________                                          72° F.                                                                         85%            85%       85%                                           110° F.                                                                         37%            46%       59%                                           ______________________________________                                    

Although all the binders are affected by temperature, the polyvinyl acetate bonded fiberfill loses more loft at 110° F. than the polymer emulsions of Examples 1 and 2.

EXAMPLE 4

A more detailed study was made of the binder utilizing the polymer emulsion prepared in Example 1 on a slightly different fabric, a 50/50 blend of 6 and 15 denier polyester. Web preparation and bonding were similar to Examples 3. Finished fiberfill weight for this furniture pad material was 18oz./yd² with a fiber content of 81% and a binder content of 19%.

The same loft recovery test was conducted at 120° F. with compression for 6 hours under various compression loads and recovery measured both immediately and after 6 hours. Again the polymer of Example 1 shows considerably more loft recovery at this temperature under all compression loads as compared to a binder utilizing a polyvinyl acetate emulsion polymer (PVAc) as shown in Table 2.

                                      TABLE 2                                      __________________________________________________________________________     Compression                                                                    Loading  0.02 psi  0.05 psi  0.15 psi                                          __________________________________________________________________________     polymer type                                                                            PVAc                                                                               Example 1                                                                            PVAc                                                                               Example 1                                                                            PVAc                                                                               Example 1                                     immediate                                                                               69% 77%   55% 68%   14% 27%                                           recovery                                                                       6 hour recovery                                                                         69% 80%   58% 70%   16% 29%                                           __________________________________________________________________________

EXAMPLE 5

Ethylene-vinylacetate copolymer emulsions, Examples E and I, were prepared as follows:

The following was charged to a 10 gal. stainless steel pressure reactor equipped with a variable agitator set at 60 rpm, temperature control system, feedpumps, means for purging the reactor with nitrogen and pressurizing with ethylene, and an internal coil for heating and cooling:

    ______________________________________                                                          Example I                                                                              Example E                                             ______________________________________                                         Water (deionized)  7500 g.   7500 g.                                           Emcol K8300 (2)    120 g.    120 g.                                            Triton X 405 (8)    85 g.     85 g.                                            Tamol SN (9)        17 g.     17 g.                                            Ferrous sulfate (10% Solution)                                                                     8 g.      8 g.                                             ______________________________________                                    

The contents of the reactor were heated to 45°-50° C., the reactor was purged with nitrogen once, and with ethylene twice to 10 psi. followed by the addition of:

    ______________________________________                                                      Example I                                                                              Example E                                                 ______________________________________                                         Vinyl acetate  400 g.    400 g.                                                ______________________________________                                    

The reactor was then pressurized with ethylene to 800 psi. This was followed by the addition of the following initial catalyst solution:

    ______________________________________                                                        Example I                                                                              Example E                                               ______________________________________                                         Water (deionized)                                                                               200 g.    200 g.                                              Ammonium persulfate                                                                              13 g.     13 g.                                              ______________________________________                                    

The polymerization was initiated by adding an activator solution at a rate of 5 g/min. which was made up as follows:

    ______________________________________                                                        Example I                                                                              Example E                                               ______________________________________                                         Water (deionized)                                                                               1500 g.   1500 g.                                             Hydrosulfite AWC (3)                                                                             50 g.     50 g.                                              ______________________________________                                    

The polymerization initiated within 5 minutes as indicated by a rise in reactor temperature.

The following monomer emulsion, prepared previously was then added gradually by means of an addition pump at a rate of 43 g/min. over a 3 hour period.

    ______________________________________                                                          Example I                                                                              Example E                                             ______________________________________                                         Water (deionized)  4000 g.   4000 g.                                           Emcol K8300 (2)    250 g.    250 g.                                            Monoethyl maleate  140 g.    140 g.                                            Ammonium hydroxide (28%)                                                                           9 g.      9 g.                                             Vinyl acetate      8300 g.   8300 g.                                           Triallyl cyanurate  1 g.      1 g.                                             Ammonium persulfate                                                                               100 g.    100 g.                                            ______________________________________                                    

The temperature of the reactor content was allowed to rise to 55° C. and was maintained there by the addition of the above mentioned activator solution as needed. At this point the ethylene pressure rose to 900 psi and was maintained there by setting the ethylene supply valve to 900 psi for Example E and to 1100 psi for Example I. A total of 1500g for Example I and 881g for Example E of the activator solution was used.

After 3-3 1/2 hours, when all the monomer emulsion and activator solution had been added to the reactor the following finishing catalyst solution was added:

    ______________________________________                                                        Example I                                                                              Example E                                               ______________________________________                                         Water (deionized)                                                                               400 g.    200 g.                                              Ammonium persulfate                                                                             25 g.     20 g.                                               T-butyl hydroperoxide                                                                           15 g.      5 g.                                               ______________________________________                                    

followed by addition of the following finishing activator solution:

    ______________________________________                                                        Example I                                                                              Example E                                               ______________________________________                                         Water (deionized)                                                                               400 g.    200 g.                                              Hydrosulfite AWC (4)                                                                             20 g.     10 g.                                              ______________________________________                                    

The temperature of the batch was maintained at 60° C. for an additional hour after which the free vinyl acetate monomer concentration had fallen below 1%. The polymer emulsion was then cooled to 30° C. and the ethylene vented from the reactor to ambient pressure. The following solution was then added to the batch:

    ______________________________________                                                          Example I                                                                              Example E                                             ______________________________________                                         Water (deionized)  500 g.    500 g.                                            Triton X 405 (8)   85 g.     85 g.                                             Ammonium hydroxide (28%)                                                                          50 g.     50 g.                                             ______________________________________                                    

The ethylene-vinylacetate copolymer emulsions had the following properties:

    ______________________________________                                                      Example I  Example E                                              ______________________________________                                         solids (30 min at                                                                             44.6%            42.3%                                          130° C. drying)                                                         pH             7.4              6.8                                            viscosity (Brookfield                                                                         41.6    cps      30.4  cps                                      at 50 RPM)                                                                     intrinsic viscosity,                                                                          1.50    dl/g     1.56  dl/g                                     (measured in N-methyl                                                          pyrrolidone at 30° C.) (6)                                              particle size (by light                                                                       0.13    microns  0.13  microns                                  transmission) (40)                                                             ethylene content of                                                                           18.5%            8.8%                                           the copolymer                                                                  ______________________________________                                    

Notes:

(8) Triton X 405 is a 70 percent solution in water of an octylphenoxypolyethoxyethanol containing 30 moles of oxyethanol per mole of octyl phenol. It is supplied by the Rohm & Haas Company.

(9) Tamol SN is a dispersant supplied by the Rohm & Haas Company.

(10) The particle size was measured by light transmission using a Coulter Counter.

EXAMPLE 6

Polymer emulsions were prepared containing an interpenetrating network of vinylacetate-ethylene copolymer and varying amounts of polystryrene.

The following was charged to a 1 liter glass reactor equipped with a variable agitator, temperature control system, feedpumps, and a water bath for heating and cooling:

    ______________________________________                                                    Ex. B    Ex. C     Ex. D                                            ______________________________________                                         Airflex 100 HS (11)                                                                         1819.8 g   1611.3 g  1392.2 g                                     Water (deionized)                                                                           474.4 g    568.7 g   361.2 g                                      Emcol K8300 (2)                                                                             7.3 g      14.7 g    21.7 g                                       Triton X 405 (8)                                                                            4.4 g      8.8 g     13.0 g                                       Sipomer DS 10 (12)                                                                          1.6 g      1.6 g     4.8 g                                        Monoethyl maleate                                                                           1.2 g      2.4 g     3.6 g                                        Styrene      112.2 g    223.3 g   330.6 g                                      Divinyl benzene                                                                             0.12 g     0.22 g    0.32 g                                       Ammonium persulfate                                                                         1.9 g      3.8 g     5.7 g                                        t-Butyl hydroperoxide                                                                       0.5 g      0.9 g     1.4 g                                        ______________________________________                                    

The batch was heated to 55° C., after equilibration the following activator solution was added:

    ______________________________________                                         Water (deionized)                                                                           4.9 g      9.7 g     14.4 g                                       Hydrosulfite AWC (3)                                                                        1.0 g      2.0 g     2.9 g                                        ______________________________________                                    

After leaving the batch at 80° C. for 2-5 hours it was then cooled to room temperature and the following solution was added:

    ______________________________________                                                         Ex. B   Ex. C   Ex. D                                          ______________________________________                                         Water             26.1 g    26.1 g  26.1 g                                     Triton X 405 (8)  13.2 g    13.2 g  13.2 g                                     Ammonium hydroxide (28%)                                                                         9.4 g     9.4 g   9.4 g                                      Formaldehyde (37%)                                                                               0.7 g     0.7 g   0.7 g                                      Proxel GXL (13)   1.4 g     1.4 g   1.4 g                                      ______________________________________                                    

The interpenetrating network containing emulsions had the following properties:

    ______________________________________                                                   Ex. B    Ex. C      Ex. D                                            ______________________________________                                         solids (30 min at                                                                          45.5%          45.3%      45.4%                                    130° C. drying)                                                         pH          5.2            7.9        4.9                                      viscosity (Brook-                                                                          49.6    cps    53.6  cps  37.6  cps                                field at 50 RPM)                                                               intrinsic viscosity                                                                        1.14    dl/g   0.99  dl/g 1.24  dl/g                               (measured in                                                                   N-methyl                                                                       pyrrolidone                                                                    at 30° C.) (6)                                                          particle size                                                                              0.16           0.18       0.19                                     (microns) (10)                                                                 free styrene                                                                               0.01%          0.11%      0.26%                                    total polystyrene                                                                          10%            20%        30%                                      content                                                                        ______________________________________                                    

Notes:

(11) Airflex 100 HS is a vinyl acetate-ethylene copolymer emulsion having an approximate ethylene content of about 15%. It is supplied by Air Proudcts and Chemicals Corp.

(12) Sipomer DS 10 is a brand of sodium dodecyl benzene sulfonate supplied by the Alcolac Chemical Co.

(13) Proxel GXL is a biocide supplied by ICI.

    __________________________________________________________________________     Example 7                                                                      Polymer emulsions were prepared containing an interpenetrating network of      vinyl acetate-ethylene (from                                                   Example 6) and varying amounts of polystyrene.                                                   Ex. F  Ex. G   Ex. H  Ex. J   Ex. K  Ex.                     __________________________________________________________________________                                                            L                       The following was charged to a 1 liter glass reactor equipped with a           variable agitator, temperature control                                         system, feedpumps, and a water bath for heating and cooling:                   Vinyl acetate-ethylene copolymer                                               (Ex. E)           277.3                                                                              g  251.4                                                                              g   225.7                                                                              g  --      --     --                      (Ex. I)           --     --      --     264.9                                                                              g   240.8                                                                              g  208.8                                                                              g                   Water (deionized) 1.4 g  3.0 g   4.7 g  1.4 g   13.3                                                                               g  22.3                                                                               g                   Monoethyl maleate 0.1 g  0.3 g   0.4 g  0.1 g   0.2 g  0.3 g                   Styrene           13.1                                                                               g  27.2                                                                               g   41.1                                                                               g  12.4                                                                               g   26.8                                                                               g  39.8                                                                               g                   Divinyl benzene   0.01                                                                               g  0.03                                                                               g   0.04                                                                               g  0.01                                                                               g   0.03                                                                               g  0.04                                                                               g                   Ammonium persulfate                                                                              0.2 g  0.3 g   0.8 g  0.2 g   0.4 g  0.6 g                   t-Butyl hydroperoxide                                                                            0.1 g  0.1 g   0.2 g  0.1 g   0.2 g  0.3 g                   The batch was heated to 55° C., after equilibration the following       activator solution was added:                                                  Water (deionized) 5.0 g  13.0                                                                               g   15.4                                                                               g  10.0                                                                               g   15.0                                                                               g  15.3                                                                               g                   Hydrosulfite AWC (3)                                                                             0.1 g  0.3 g   0.3 g  0.2 g   0.3 g  0.3 g                   After initiation which was observed by an increase in temperature, the         following emulsifier solution was                                              added over 15 minutes:                                                         Water (deionized) 2.9 g  5.8 g   9.0 g  2.9 g   6.0 g  8.9 g                   Emcol K8300 (2)   0.9 g  1.8 g   2.8 g  0.6 g   1.8 g  1.9 g                   Triton X 405 (8)  0.6 g  1.1 g   1.7 g  0.9 g   1.3 g  2.7 g                   Sipomer DS 10 (12)                                                                               0.2 g  0.4 g   0.6 g  0.2 g   0.4 g  0.6 g                   After leaving the batch at 57-58° C. for 2 hours it was then            cooled to room temperature and the following                                   solution was added:                                                            Water             4.1 g  4.1 g   4.1 g  4.1 g   4.1 g  4.1 g                   Triton X 405 (8)  2.1 g  2.1 g   2.1 g  2.1 g   2.1 g  2.1 g                   Ammonium hydroxide (28%)                                                                         1.5 g  1.5 g   1.5 g  1.5 g   1.5 g  1.5 g                   Formaldehyde (37%)                                                                               0.1 g  0.1 g   0.1 g  0.1 g   0.1 g  0.1 g                   Proxel GXL (13)   0.2 g  0.2 g   0.2 g  0.2 g   0.2 g  0.2 g                   The interpenetrating network containing emulsions had the following            properties:                                                                    solids (30 min at 130° C. drying)                                                         42.7%  42.7%   42.3%  44.5%   45.5%  45.5%                   pH                5.3    7.0     6.0    5.45    5.3    5.4                     viscosity (Brookfield at 50 RPM)                                                                 27.2                                                                               cps                                                                               32.0                                                                               cps 138.4                                                                              cps                                                                               39.2                                                                               cps 36.0                                                                               cps                                                                               37.6                                                                               cps                 intrinsic viscosity (measured in                                                                 1.85                                                                               dl/g                                                                              1.25                                                                               dl/g                                                                               1.24                                                                               dl/g                                                                              1.64                                                                               dl/g                                                                               1.38                                                                               dl/g                                                                              1.31                                                                               dl/g                N-methyl pyrrolidone at 30° C.) (6)                                     particle size, microns (10)                                                                      0.15   0.21    0.29   0.15    0.19   0.21                    free styrene      0.48%  0.61%   0.58%  0.33%   0.35%  0.85%                   polystyrene content                                                                              10%    20%     30%    10%     20%    30%                     __________________________________________________________________________

EXAMPLE 8

A series of paper coating formulations were made with vinylacetate-ethylene copolymer emulsions (Example 5) and with the same copolymer emulsions after a second stage polymerization with styrene to form an interpenetrating polymer network (IPN) of the copolymer emulsion with polystyrene (see Examples 6 and 7). Three basic vinylacetate-ethylene (VAE) emulsions were used as follows: a commercial product, Airflex 100 HS sold by Air Products and Chemicals Corp., containing about 15% ethylene and with a Tg of +5° C.; an emulsion containing 8.8% ethylene (Example E) and with a Tg of 15° C.; and an emulsion containing 18.5% ethylene (Example I) and with a Tg of 0° C. All three VAE copolymer emulsions were further swelled by styrene monomer and polymerized as described in Examples B-D, F-H and J-L (Examples 6 and 7). The particle sizes and of the VAE and IPN emulsions are summarized as follows in Table 3:

                  TABLE 3                                                          ______________________________________                                         Example Emulsion Description                                                                               Particle Size(1)                                   ______________________________________                                         A       Airflex 100HS (15% Ethylene)                                                                       0.160 μm                                        B       with 10% Styrene    0.162 μm                                        C       with 20% Styrene    0.182 μm                                        D       with 30% Styrene    0.192 μm                                        E       VAE with 8.8% Ethylene                                                                             0.134 μm                                        F       with 10% Styrene    0.148 μm                                        G       with 20% Styrene    0.205 μm                                        H       with 30% Styrene    0.292 μm                                        I       VAE with 18.5% Ethylene                                                                            0.127 μm                                        J       with 10% Styrene    0.149 μm                                        K       with 20% Styrene    0.191 μm                                        L       with 30% Styrene    0.207 μm                                        ______________________________________                                    

All emulsions of Examples A thru L were made into paper coating formulas of the following dry composition:

    ______________________________________                                                          Dry Weight (gms.)                                             ______________________________________                                         Kaolin Clay        350.0                                                       Anionic Dispersant 5.3                                                         Ethoxylated Starch 7.0                                                         Emulsion from Examples A-L                                                                        18.9                                                        ______________________________________                                    

As in standard paper coating formulation, the clay (ground clay, 92-94% finer than 2 microns) and dispersant (Dispex N-40 from Allied Corporation) were ground together in a Kady Mill at 70% solids for 30 minutes. Separately the starch (Penford Gum 280 from Penick & Ford Ltd.) was slurried at 25% solids and cooled at 190° F. for 20 minutes. This starch mix was added to the clay and dispersant mix and agitated The polymer emulsions were then added to this composite mix and the coating formulation diluted to 64% solids for coating.

The relative performance of a paper in a printing press can be simulated in various laboratory tests. Offset printing is demanding on paper coatings. The coating is first wet with a water/alcohol solution and then printed with a thick, tacky ink. The multi-color printing there may be four or five applications in less than a second on a high speed press.

A 50#/ream groundwood-free base sheet was coated with 8#dry coat weight (CIS, coated on one side) on a bench paper coater made by Modern Metalcraft Company. This coated paper was then calendered 2 nips at 150 F under a 600 pli pressure in a cotton/steel calender. After conditioning 24 hours under standard paper test conditions the paper coatings were tested for sheet gloss, smoothness, porosity, pick strength, Adam wet rub resistance, printed ink gloss and SIWA brightness. Sheet gloss, smoothness and porosity showed little variation between the vinylacetate-ethylene (VAE) emulsions and the interpenetrating polymer network (IPN) emulsions formed by the second stage polymerization with styrene.

The effect of the second stage polymerizations in forming the IPN emulsions was apparent in pick strength, Adam wet rub resistance, printed ink gloss, and SIWA brightness tests. The results are as follows:

                  TABLE 4                                                          ______________________________________                                         IGT Pick   Adam's Wet   75° Ink                                                                          SIWA (6)                                      Strength (3)                                                                              Rub (4)      Gloss (5)                                                                               Brightness                                    ______________________________________                                         A   22          72          96     51.5                                        B   28         136          97     49.6                                        C   23         190          96     53.3                                        D   22         196          91     55.5                                        E   22          72          96     51.5                                        F   29         124          96     49.8                                        G   22         126          91     52.2                                        H   16         390          81     59.5                                        I   20         165          92     52.3                                        J   26         111          96     54.0                                        K   25         155          94     56.1                                        L   22         219          91     61.3                                        ______________________________________                                    

An additional evaluation compares the IPN emulsion with physical blends of an equivalent composition (i.e. blend of the vinylacetate-ethylene copolymer with a corresponding level of polystryrene). The blends are designated with an (').

                  TABLE 5                                                          ______________________________________                                                IGT Pick                                                                       Strength                                                                              Adam's Wet 75° Ink                                                                           SIWA (17)                                          (14)   Rub (15)   Gloss (16)                                                                               Brightness                                  ______________________________________                                         H(IPN)   16       390        81      59.5                                      H' (Blend)                                                                              13       206        81      56.3                                      J(IPN)   26       111        96      54.0                                      J' (Blend)                                                                              26       251        91      58.9                                      L(IPN)   22       219        91      61.3                                      L' (Blend)                                                                              13       296        80      58.9                                      ______________________________________                                    

Notes

(14) The coating must be strong enough not to `pick` when the ink applicator rolls off the surface. This is especially important on high speed presses and with tackier inks. The IGT pick strength (reported as a product of velocity and viscosity--VVP) is determined by using different viscosity oils and applying them at different speeds until the coating fails (picks). This establishes the coating's pick strength Pick strength was measured on an AlC2-5 Model IGT pick tester sold by Techno Graphic Instruments. The test was run with a setting of 2m/s using LV oil and a pressure setting of 50 kg. LV oil is polybutene with a viscosity of 242 poise at 23° C. Pick Values in VVP (velocity-viscosity product as defined by IGT) are reported.

(15) The coating must accept the water solution but not soften or release pigment to the press (called `milking` by printers). This is simulated by the Adams wet rub test in which the coating is wetted and rubbed mildly for 20 seconds. The amount of `milking` is measured by the amount of coating removed (in milligrams) or by the opacity of the water solution.

(16) The ink must wet the coating but not absorb into the paper and lose its sharpness. This is measured as ink gloss on a glossmeter. Printed ink gloss was determined by placing a 4.8 um ink film on the coated paper and measuring gloss on a 75. Gardner Glossmeter II.

(17) In actual practice the ink may be applied over a previous water layer. If the paper does not absorb water sufficiently, the ink will not apply and the coating layer will remain unprinted. The simultaneous application of ink over water and subsequent measure of coverage is measured by SIWA brightness. High brightness numbers indicate less complete ink overage because the unprinted coating is brighter than the ink. SIWA brightness is a simulation of an offset printing process conducted on an IGT pick tester. A droplet of water is overprinted with ink (Control-Lith II Blue from GPI Division of Sun Chemical Corporation) on a 15 micron printing disc at 2m/s. The brightness of the overprinted area is then measured on a GP Photovolt brightness meter. Higher brightness values indicate higher water holdout tendencies.

In all cases the second styrene polymerization forming the IPN emulsion increased the IGT pick strength. In fact, levels of about 10% styrene produced a maximum coating strength in all three vinylacetate-ethylene systems. Increasing from 10% to 30% styrene reduced pick strength back to the level of the original vinylacetate-ethylene emulsion probably due to the increased particle size at higher styrene levels. Both particle size and polymer composition affect paper coatings. Generally, with a given polymer composition, smaller polymer particle sizes will produce higher strength paper coatings. Here, for the various IPN polymers the particle size/strength relationship is not clear because of the differing polymer compositions. However, it is clear that the second polymerization of the IPN polymers increased the paper coating strength since even though the particle size increased, the IGT peek strength was greater than in the non-IPN polymer paper coatings.

Adam's wet rub results deteriorated with increasing styrene levels for Examples A-D and E-H but showed improvement in Examples J and K. Ink gloss (75.) also showed increases at lower levels of styrene, but a subsequent decrease in gloss at higher styrene levels SIWA brightness increased with increasing styrene levels, with two systems decreasing slightly at low styrene levels, but increasing rapidly with further increases of styrene levels. In the above Examples IPN emulsions containing 10% styrene produced peak values in IGT strength and ink gloss.

Blending a polystyrene emulsion with the vinylacetate-ethylene copolymer emulsion did not produce the same results as forming an IPN emulsion with polystyrene in a second phase polymerization. The differences (shown in Table 5) are most pronounced in IGT pick strength, Adam's wet rub and 75° ink gloss. These are the three most important measures for predicting offset press runnability of coated papers and the improvements show the potential value of this invention on paper coating applications. Importantly this IPN emulsion can deliver excellent performance at a low cost since the starting materials are relatively low cost polymers.

EXAMPLE 9

A polyvinyl acetate emulsion was prepared as follows.

The following was charged to a 100 gallon stainless steel pilot reactor equipped with a variable agitator, temperature control system, feedpumps, means for purging the reactor with nitrogen, and a jacket for heating and cooling:

    ______________________________________                                         Water             140 lbs. (63.5 kg)                                           Triton X305 (1)    6 lbs. 10 oz. (3 kg)                                        Emcol K8300 (2)    8 oz. (227 g)                                               ______________________________________                                    

The contents of the reactor were heated to 67° C. after which the reactor was purged with nitrogen. After the heat-up and purge the following monomer was added to the reactor:

    ______________________________________                                         Vinyl acetate 26 lbs. (11.8 kg)                                                ______________________________________                                    

This was followed by the addition of the initial catalyst solution:

    ______________________________________                                         Water                10 lbs. (4.5 kg)                                          Potassium persulfate  8 oz. (227 g)                                            ______________________________________                                    

The polymerization initiated within 5 minutes as indicated by a rise in temperature of the reactor. The following monomer emulsion, made up previously, was then added gradually by means of an addition pump at a rate of 1.56 lbs./minute over a 31/2 hour period:

    ______________________________________                                         Water                 58 lbs. (26.3 kg)                                        Emcol K8300.sup.(2)   8 lbs. 8 oz. (3.9 kg)                                    Triton X 305.sup.(1)  2 lbs. 4 oz. (1.0 kg)                                    N-Methylol acrylamide (49%)                                                                          19 lbs. (8.6 kg)                                         Acrylamide (50%)      2 lbs. (0.9 kg)                                          Monoethylmaleate      12 oz. (340 g)                                           JPS Sequesterent.sup.(5)                                                                             5 oz. (142 g)                                            Vinyl acetate        238 lbs.(108 kg)                                          Triallyl cyanurate    5 oz. (142 g)                                            ______________________________________                                    

The temperature of the reactor content was allowed to rise to 80° C. and was maintained there by the gradual addition at a rate of 0.362 lbs./minute over a 31/2 hour period of the following catalyst solution:

    ______________________________________                                         Water                75 lbs. (34 kg)                                           Potassium persulfate  9 oz. (225 g)                                            ______________________________________                                    

After 31/2 hours, when all the monomer emulsion and catalyst solution had been added to the reactor the following finishing catalyst solution was added:

    ______________________________________                                         Water                1 lb. (.45 kg)                                            Potassium persulfate 2 oz. (57 g)                                              ______________________________________                                    

The temperature of the batch was maintained at 80° C. for an additional 30 minutes, after which the polymer emulsion was cooled to 30° C.

The copolymer emulsion thus obtained had the following properties:

    ______________________________________                                         solids (30 min at 130° C. drying                                                                 43.9%                                                 pH                        5.5                                                  viscosity (Brookfield at 50 RMP)                                                                        36.8 cps                                              ______________________________________                                    

EXAMPLE 10

A polystyrene emulsion was prepared as follows:

The following was charged to a 3 liter stainless steel laboratory reactor equipped with a variable agitator, temperature control system, feedpumps, means for purging the reactor with nitrogen, and a waterbath for heating and cooling:

    ______________________________________                                         Water             850 g                                                        Triton X 305.sup.(1)                                                                              18 g                                                        Ferrous sulfate    1 g                                                         (1% solution in water)                                                         ______________________________________                                    

The contents of the reactor were heated to 68° C. after which the reactor was purged with nitrogen. After the heat-up and purge the following monomer was added to the reactor:

    ______________________________________                                                Styrene                                                                               129 g                                                            ______________________________________                                    

This was followed by the addition of the initial catalyst solution:

    ______________________________________                                         Water                  129    g                                                Potassium persulfate   2.6    g                                                ______________________________________                                    

The polymerization initiated within 5 minutes as indicated by the rise in temperature of the reactor. The following monomer emulsion, made up previously, was then added gradually by means of an addition pump at a rate of 9 g/minutes over a 3 hour period:

    ______________________________________                                         Water               284 g                                                      Emcol K8300.sup.(2) 40 g                                                       Triton X 305.sup.(1)                                                                               30 g                                                       N-Methylol acrylamide (49%)                                                                        93 g                                                       Acrylamide (50%)    10 g                                                       Styrene             1148 g                                                     Itaconic acid       15 g                                                       Triallyl cyanurate    1.2 g                                                    Ammonium hydroxide (28%)                                                                           to a pH of 3.6                                             ______________________________________                                    

The temperature of the reactor content was allowed to rise to 74°-75° C. and was maintained there by the gradual addition at a rate of 0.73 g/minute over a 3 hour period of the following catalyst solution:

    ______________________________________                                         Water             129 g                                                        Potassium persulfate                                                                              2 g                                                         ______________________________________                                    

After 3 hours, when all the monomer emulsion had been added to the reactor the following finishing catalyst solution was added:

    ______________________________________                                         Water             20 g                                                         t-Butyl hydroperoxide                                                                             1 g                                                         ______________________________________                                    

followed by a reducing solution:

    ______________________________________                                         Water                   2     g                                                Hydrosulfite AWC.sup.(3)                                                                               0.5   g                                                ______________________________________                                    

The temperature of the batch was maintained at 70° C. for an additional 30 minutes, after which the polymer emulsion was cooled to room temperature. The copolymer emulsion thus obtained had the following properties:

    ______________________________________                                         solids (30 min at 130° C. drying)                                                               44.9%                                                  pH                      5.5                                                    viscosity (Brookfield at 50 RPM)                                                                       46.4 cps                                               intrinsic viscosity (measured in                                                                       1.44 dl/g                                              N-methyl pyrrolidone at 30° C.).sup.(6)                                 particle size (by light 0.16 microns                                           transmission) .sup.(10)                                                        free styrene monomer    0.25%                                                  ______________________________________                                    

EXAMPLE 11

A blend was made by mixing the following polymer emulsions:

    ______________________________________                                         emulsion of Example 9                                                                             817.2 g                                                     emulsion of Example 10                                                                            532.8 g                                                     ______________________________________                                    

The emulsion blend had the following properties:

    ______________________________________                                         solids (30 min at 130.C drying)                                                                        44.3%                                                  pH                       5.25                                                  viscosity (Brookfield at 50 RPM)                                                                       40 cps                                                 intrinsic viscosity (measured                                                                          1.21 dl/g                                              N-methyl pyrrolidone at 30° C.).sup.(6)                                 particle size.sup.(10)  0.18 microns                                           ______________________________________                                    

EXAMPLE 12

A emulsion containing a polymer which is an interpenetrating network of 60% polyvinyl acetate and 40% polystyrene was prepared as follows.

The following was charged to a 3 liter stainless steel laboratory reactor equipped with a variable agitator, temperature control system, feedpumps, means for purging the reactor with nitrogen, and a water bath for heating and cooling:

    ______________________________________                                         Water                 462    g                                                 Triton X305.sup.(1)   18     g                                                 Emcol K8300.sup.(2)   0.6    g                                                 ______________________________________                                    

The content of the reactor were heated to 67° C. after which the reactor was purged with nitrogen. After the heat-up and purge the following monomer was added to the reactor:

    ______________________________________                                                Vinyl acetate                                                                           72 g                                                           ______________________________________                                    

This was followed by the addition of the initial catalyst solution:

    ______________________________________                                         Water                  24     g                                                Potassium persulfate   1.32   g                                                ______________________________________                                    

the polymerization initiated within 5 minutes as indicated by a rise in temperature of the reactor. The following monomer emulsion, made up previously, was then added gradually by means of an addition pump at a rate of 7.11 g/minute over a 126 minute period:

    ______________________________________                                         Water                   158    g                                               Emcol K8300.sup.(2)     22.8   g                                               Triton X305.sup.(1)     5.88   g                                               N-Methylol acrylamide(49%)                                                                             51.6   g                                               Acrylamide (50%)        6      g                                               Monoethylmaleate        1.98   g                                               Vinyl acetate           648    g                                               Triallyl cyanurate      0.72   g                                               ______________________________________                                    

The temperature of the reactor content was allowed to rise to 80° C. and was maintained there by the gradual addition at a rate of 1.16 g/minute over a 126 minute period of the following catalyst solution:

    ______________________________________                                         Water                  144    g                                                Potassium persulfate   1.56   g                                                ______________________________________                                    

The temperature of the batch was maintained at 80° C. for an additional 30 minutes, after which the polymer emulsion was cooled to 60° C. and an additional 240 g of water was added. Then a second monomer emulsion was introduced into the reactor as fast as possible, in about 10 minutes, which also had been prepared before as follows:

    ______________________________________                                         Water                   216    g                                               Emcol K8300.sup.(2)     21.6   g                                               Triton X 305.sup.(1)    21.6   g                                               N-Methylol acrylamide (49%)                                                                            36     g                                               Styrene                 489    g                                               Divinylbenzene          0.48   g                                               Sipomer DS-10.sup.(12)  7.2    g                                               Itaconic acid           7.2    g                                               ______________________________________                                    

The temperature of the reactor content was maintained at 60° C. while the reactor was again purged with nitrogen. Then the following catalyst solution was added to the reactor:

    ______________________________________                                         Water                  180    g                                                Potassium persulfate   7.2    g                                                t-butyl hydroperoxide  2.4    g                                                ______________________________________                                    

The second polymerization step was initiated by adding half of the following reducing solution:

    ______________________________________                                         Water                   90    g                                                Hydrosulfite AWC.sup.(4)                                                                               3.6   g                                                ______________________________________                                    

The temperature of the batch increased rapidly to 80° C., at which point the other half of the reducing solution was added to the reactor. The temperature of the batch was then maintained at about 80° C. for an additional 30 minutes, after which the polymer emulsion was cooled to room temperature. The following post-add was then added:

    ______________________________________                                         Water                  5      g                                                Proxel GXL.sup.(13)    0.25   g                                                Formaldehyde (37%)     0.25   g                                                ______________________________________                                    

The interpenetrating network copolymer emulsion thus obtained had the following properties:

    ______________________________________                                         solids (30 minutes at 130° C.                                                                 42.5 g                                                   drying)                                                                        pH                    5.5                                                      viscosity (Brookfield at                                                                             670 cps                                                  50 RPM)                                                                        intrinsic viscosity (measured                                                                        0.85 dl/g                                                in N-methyl pyrrolidone at                                                     30° C.).sup.(6)                                                         particle size.sup.(10)                                                                               0.37 microns                                             ______________________________________                                    

EXAMPLE 13

An ethylene-vinyl acetate copolymer emulsion was prepared as follows.

The following was charged to a 10 gal. stainless steel pressure reactor equipped with a variable agitator, temperature control system, feedpumps, means for purging the reactor with nitrogen and pressurizing with ethylene, and an internal coil for heating and cooling:

    ______________________________________                                         Water (deionized)     9250   g                                                 Triton X 405.sup.(8)  120    g                                                 Triton X 100.sup.(18) 85     g                                                 Ferrous sulfate       0.2    g                                                 ______________________________________                                    

The contents of the reactor were heated to 40° C., the reactor was purged with nitrogen once, and then the reactor was pressurized with ethylene to 800 psi. After the heat-up, purge and pressurization, 1000 g of the following monomer emulsion, made up previously, was added to the reactor:

    ______________________________________                                         Water (deionized)    2600 g                                                    Emcol K8300.sup.(2)  100 g                                                     Triton X 405.sup.(8) 220 g                                                     Triton X 100.sup.(18)                                                                               150 g                                                     N-Methylol acrylamide (49%)                                                                         565 g                                                     Acrylamide (50%)     565 g                                                     Sodium persulfate     46 g                                                     Vinyl acetate        7700 g                                                    Triallyl cyanurate    12 g                                                     ______________________________________                                    

This was followed by the addition of the following initial catalyst solution:

    ______________________________________                                         Water (deionized) 385 g                                                        Sodium persulfate  38 g                                                        ______________________________________                                    

The polymerization was initiated by adding an activator solution at a rate of 1.25 g/min as follows:

    ______________________________________                                         Water (deionized) 420 g                                                        Hydrosulfite-AWC.sup.(3)                                                                          25 g                                                        ______________________________________                                    

The polymerization initiated within 5 minutes as indicated by a rise in the reactor temperature. The rest of the monomer emulsion was then added gradually by means of an addition pump at a rate of 30 g/minute over a 3 hour period. The temperature of the reactor content was allowed to rise to 60° C. and was maintained there by the addition of the above mentioned activator solution as needed. At this point the ethylene pressure rose to 900 psi and was maintained there by setting the ethylene supply valve to 900 psi. A total of 445 g of the activator solution was used.

After 3 hours, when all the monomer emulsion and activator solution had been added to the reactor the following finishing catalyst solution was added:

    ______________________________________                                         Water                  77     g                                                Sodium persulfate      8      g                                                t-butyl hydroperoxide  7.5    g                                                Triton X 4 5.sup.(8)   2      g                                                ______________________________________                                    

followed by addition of the following finishing activator solution:

    ______________________________________                                         Water (deionized) 77 g                                                         Hydrosulfite AWC.sup.(3)                                                                          8 g                                                         ______________________________________                                    

The temperature of the batch was maintained at 60° C. for an additional hour after which the free vinyl acetate monomer concentration had fallen below 1%. The polymer emulsion was then cooled to 30° C. and the ethylene vented from the reactor to ambient pressure. The ethylene vinyl acetate copolymer emulsion had the following properties:

    ______________________________________                                         solids (30 minutes at 130° C.                                                                 42.1%                                                    drying)                                                                        pH                    5.85                                                     viscosity (Brookfield at                                                                             142 cps                                                  50 RPM)                                                                        intrinsic viscosity (measured                                                                        0.8 dl/g                                                 in N-methyl pyrrolidone at                                                     30° C.).sup.(6)                                                         particle size.sup.(10)                                                                               0.14 microns                                             ethylene content of the                                                                              18.5%                                                    copolymer                                                                      ______________________________________                                    

Note:

(18) Triton x 100 is an octylphonoxy polyethoxyethanol containing 10 moles of oxyethanol per mole of octylphenol. It is supplied by the Rohm & Hass Company.

EXAMPLE 14

An emulsion containing a polymer which is an interpenetrating network of an ethylene-vinyl acetate copolymer and polystryrene was prepared as follows:

The following was charged to a 1 liter glass reactor equipped with a variable agitator, temperature control system, feedpumps, and a water bath for heating and cooling:

    ______________________________________                                         Emulsion of Example 13                                                                             250.9 g                                                    Water (deionized)   44.3 g                                                     Emcol K8300.sup.(2) 1.4 g                                                      Triton X 305.sup.(1)                                                                               1.4 g                                                      N-Methylol acrylamide (49%)                                                                        2.4 g                                                      Styrene             47.7 g                                                     Divinyl benzene      0.05 g                                                    Potassium persulfate                                                                               0.5 g                                                      t-Butyl hydroperoxide                                                                              0.3 g                                                      ______________________________________                                    

The batch was heated to 55° C. after which the following activator solution was added:

    ______________________________________                                         Water (deionized) 8.1 g                                                        Hydrosulfite AWC.sup.(3)                                                                         0.2 g                                                        ______________________________________                                    

After leaving the batch at 57° C. for 3 hours the above activator and catalyst charge was repeated and kept at 65° C. for an additional hour. The batch was then cooled to room temperature. The interpenetrating network containing emulsion had the following properties:

    ______________________________________                                         solids (30 minutes at 130° C.                                                                 42.6%                                                    drying)                                                                        pH                    5.5                                                      viscosity (Brookfield at                                                                             264 cps                                                  50 RPM)                                                                        intrinsic viscosity (measured                                                                        0.80 dl/g                                                in N-methyl pyrrolidone at                                                     30° C.).sup.(6)                                                         particle size.sup.(10)                                                                               0.19 microns                                             free styrene          0.5%                                                     ______________________________________                                    

EXAMPLE 15

A blend was made by mixing the following polymer emulsions:

    ______________________________________                                         emulsion of Example 13                                                                           2115.7 g                                                     emulsion of Example 10                                                                            884.3 g                                                     ______________________________________                                    

The emulsion blend had the following properties:

    ______________________________________                                         solids (30 minutes at 130°                                                                      43.7%                                                  drying)                                                                        pH                      5.4                                                    viscosity (Brookfield at                                                                               123 cps                                                50 RPM)                                                                        ______________________________________                                    

EXAMPLE 16

The following aqueous coatings were prepared using the emulsions of Examples 9 (polyvinyl acetate), 11 (blend of polyvinyl acetate and polystyrene), 12 (IPN of polyvinyl acetate and polystyrene), 14 (IPN of ethylene-vinyl acetate copolymer and polystyrene) and 15 (blend of ethylene-vinyl acetate copolymer and polystyrene).

The emulsions and the emulsion blend were formulated into aqueous coatings in the following manner. To a titanium dioxide slurry was added water, butyl cellosolve (were applicable), and then the emulsion was added under agitation. The following table lists the amounts.

                  TABLE 6                                                          ______________________________________                                         Amount of Ingredient (grams)                                                                               Butyl                                              Type    TiO.sub.2 slurry.sup.(19)                                                                  Water   cellosolve.sup.(20)                                                                      Emulsion                                 ______________________________________                                         M (Ex. 9)                                                                              239.9       62      --        400                                      N (Ex. 14)                                                                             245.9         65.4  --        400                                      O (Ex. 12)                                                                             235.4         64.5  8         400                                      P (Ex. 11)                                                                             239.9       54      --        400                                      Q (Ex. 15)                                                                             239.4       53      --        400                                      ______________________________________                                    

Note:

(19) The titanium dioxide slurry (78.2% solids) contained 65% rutile titanium dioxide, 6.6% methacrylate resin and 6.6% butyl cellosolve. It was sold under the name "Titanium Dioxide White 1060Q" by Universal Color Dispersions Company.

Note:

(20) Butyl cellosolve is a brand of ethylene glycol monobutyl ether sold by Union Carbide Corporation.

The coatings were applied to steel panels (QD panels made by the Q-Panel Company) by drawing down the liquid coating compositions with an eight mil doctor blade. The panels were oven dried at 130 F for 20 minutes and then baked for 3 minutes at 300° F. The following tests were used to evaluate the panels:

Abrasion resistance (wear): ASTM Test No. D-968, falling sand method. The higher the number, the better the abrasion resistance

Reverse and direct impact resistance: ASTM Test D-2794. The higher the number the better the impact resistance.

Adhesion: ASTM Test D-3359. The % of film removed with tape is measured with a lower number indicating better adhesion.

Gloss: ASTM Test D-523. The higher the number the better the gloss.

Film Hardness by pencil: ASTM Test D-3363. 1B is the softest rating, and 6H is the hardest rating.

Modulus of the polymer: The modulus was measured at 40° C. (E¹ ×10⁸) determined using a dynamic mechanical thermal analyzer made by Polymer Laboraties Limited. The higher number indicates a stiffer polymer film.

Table 7 lists the results of the tests.

                                      TABLE 7                                      __________________________________________________________________________                                Pencil                                                            Impact       Hardness                                            Sample                                                                             Modulus                                                                             Adhesion                                                                            Direct/Reverse                                                                          Wear                                                                               Scratch/Gouge                                                                           Gloss                                      __________________________________________________________________________     M   3.41 7.5  0.5/0.5  31.8                                                                               2H/5H    47.1                                       N   10.7 2.5  80+/-    59.2                                                                               2B/HB    39.3                                       O   2.08 20   1.5/1.5  22.2                                                                               2H/3H    57.0                                       P   2.41 29   0.5/0.5  21.8                                                                               2H/5H    36.6                                       Q   7.36 0    -/80+    69.0                                                                               2B/HB    18.5                                       __________________________________________________________________________

Although the film of the interpenetrating network of the vinyl acetate-ethylene copolymer and polystyrene (sample N), is relatively soft the modulus of the film is surprisingly high, denoting a stiff film. The impact resistance and wear properties of this polymer are also outstanding. The blend of polyvinyl acetate and polystyrene (sample P) is inferior to the interpenetrating network of polyvinyl acetate and polystyrene (sample O) in impact resistance and wear, although the modulus of the films are about equal. The gloss of the coatings of the IPN samples N and O when compared to their respective blends in samples P and Q showed a significant increase. These results show that the emulsions containing the interpenetrating networks can be used to provide superior coatings binders. 

What is claimed is:
 1. An industrial and architectural coating composition comprising: a prime pigment, a dispersant for the pigment and an aqueous polymer emulsion containing a first polymer network which is crosslinked and which is mixed and intertwined on a molecular scale with a second polymer network wherein the second polymer differs from the first polymer and the first polymer comprises 5 to 95% on a solids by weight basis of the emulsion and the monomers of the first polymer and the second polymer are not readily copolymerizable.
 2. Composition of claim 1 wherein the first polymer network contains a polymer chosen from the group consisting of polyethylene, polyester, polyurethane, polyvinyl acetate, vinylacetate-ethylene copolymer, vinylchloride-ethylene copolymer, polyvinylpropionate and vinylacetate-acrylic copolymer and the second polymer network is chosen form the group consisting of polystyrene, polymethyl methacrylate, polyacrylonitrile, polybutylacrylate, polybutadiene, styrene-butadiene copolymer, acrylonitrile-acrylate copolymer and styrene-acrylic copolymer.
 3. Composition of claim 2 wherein the first polymer network contains a vinylacetate-ethylene copolymer and the second polymer network contains styrene.
 4. Composition of claim 3 wherein the second polymer network comprises 5 to 40% on a solids by weight basis of the emulsion.
 5. Composition of claim 1 further comprising an extender pigment.
 6. Composition of claim 5 further comprising a wetting agent.
 7. An industrial and architectural coating composition comprising a prime pigment, a dispersant for the pigment and an aqueous polymer emulsion prepared by the process comprising:a) forming a first polymer emulsion which is crosslinked; b) mixing a second monomer with the first polymer emulsion whereby an emulsion mixture of the first polymer emulsion and a second monomer emulsion is obtained; c) allowing the emulsion mixture to equilibrate; and d) then polymerizing the emulsion mixture providing a first polymer network which is mixed and intertwined on a molecular scale with the second polymer network, wherein the second polymer differs from the first polymer and wherein the monomers of the first polymer and the second polymer are not readily copolymerizable and the first polymer comprises 5 to 95% on a solids by weight basis of the emulsion mixture.
 8. Composition of claim 7 wherein the first polymer network contains a polymer chosen from the group consisting of polyethylene, polyester, polyurethane, polyvinyl acetate, vinylacetate-ethylene copolymer, vinylchloride-ethylene copolymer, polyvinylpropionate and vinylacetate-acrylic copolymer and the second polymer network is chosen from the group consisting of polystyrene, polymethyl methacrylate, polyacrylonitrile, polybutylacrylate, polybutadiene, styrene-butadiene copolymer, acrylonitrile-acrylate copolymer and styrene-acrylic copolymer.
 9. Composition of claim 8, wherein the first polymer network contains a vinylacetate-ethylene copolymer and the second polymer network contains styrene.
 10. Composition of claim 9 wherein the second polymer network comprises 5 to 40% on a solids by weight basis of the emulsion.
 11. Composition of claim 7 further comprising an extruder pigment.
 12. Composition of claim 11 further comprising a wetting agent. 